Tailgate synchronizer

ABSTRACT

A tailgate synchronizer for coordinating mechanical communication between first and second handles mounted to a tailgate and first and second lock assemblies that selectively lock the tailgate to a vehicle body includes a first lock assembly actuator lever rotatably mounted to the tailgate. The first lock assembly actuator lever is selectively movable by the first handle. The first lock assembly actuator lever is connected to the first lock assembly so that the first lock assembly actuator lever unlocks the first lock assembly when sufficiently moved by the first handle. A second lock assembly actuator lever is rotatably mounted to the tailgate and selectively movable by the second handle. The second lock assembly actuator lever is connected to the second lock assembly so that the second lock assembly actuator lever unlocks the second lock assembly when sufficiently moved by the second handle.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application claims priority of Provisional Patent Application Ser.No. (unknown), filed Jun. 30, 2004, entitled “DUAL MODE TAILGATE CONTROLSYSTEM” (Attorney Docket No. HONZ 2 00025P). This application is relatedto the U.S. patent application entitled “VEHICLE LOCK ASSEMBLY”(Attorney Docket No. HONZ 2 00041), filed concurrently herewith,commonly assigned to Honda Motor Co., Ltd. and expressly incorporatedherein by reference. This application is also related to the U.S. patentapplication entitled “DUAL MODE TAILGATE CONTROL SYSTEM” (AttorneyDocket No. HONZ 2 00025), filed concurrently herewith, commonly assignedto Honda Motor Co., Ltd. and expressly incorporated herein by reference.

BACKGROUND

The present invention relates to tailgates and, more particularly, to acontrol system for a dual-mode tailgate. In one embodiment, the tailgatecontrol system is provided for controlling a dual-mode tailgate mountedto a sport utility truck or vehicle and will be described withparticular reference thereto. It is to be appreciated, however, that theinvention may relate to other similar environments and applications.

Tailgates and, more particularly, dual-mode tailgates are generallyknown. For example, U.S. Pat. No. 3,387,406 issued to Coker discloses adual-mode tailgate for use on a station wagon. “Dual-mode” refers to thetwo directions or pivot axes along which a dual-mode tailgate isopenable. Often, the dual-mode tailgate is selectively openable in afirst, fold-down direction about an axis generally parallel with a rearedge of the vehicle along which the tailgate is disposed (e.g., similarto a conventional pick-up truck tailgate). The dual-mode tailgate isalso selectively openable in a second, side-to-side direction about anaxis generally parallel with a vertical edge defining the opening inwhich the tailgate is disposed.

Generally, a dual-mode tailgate includes a dual-mode hinge pivotallyconnecting the tailgate to a vehicle, a first hinge/lock assembly spacedapart from the dual-mode hinge in a first direction and a secondhinge/lock assembly spaced apart from the dual-mode hinge in a seconddirection. For example, the dual-mode hinge is positioned in alower-left corner of the tailgate, the first hinge/lock assembly ispositioned in an upper-left corner of the tailgate and the secondhinge/lock assembly is positioned in a lower right corner of thetailgate.

When the first hinge/lock is detached from the vehicle, the tailgate isopenable in a first mode (e.g., flip-down mode) wherein the secondhinge/lock and the dual-mode hinge cooperate to pivotally connect thetailgate to the vehicle along a first axis (e.g., an axis generallyparallel with a bottom edge of an opening in which the tailgate isdisposed). When the second hinge/lock is detached from the vehicle, thetailgate is openable in a second mode (e.g., swing-open mode) whereinthe first hinge/lock assembly and the dual-mode hinge cooperate topivotally connect the tailgate to the vehicle along a second axis (e.g.,an axis generally parallel with a vertical edge of an opening in whichthe tailgate is disposed). Often, a conventional lock assembly isprovided in a corner of the tailgate cater-corner or diagonally oppositethe dual-mode hinge to further secure the tailgate to the vehicle whenthe tailgate is in a closed position.

Typically, one or more handles are provided for opening the tailgate ineach of its dual modes. The one or more handles are connected to thefirst and second hinge/lock assemblies and each of the one or morehandles can be adapted for opening the tailgate in each of its dualmodes. To prevent damage to the vehicle and the tailgate, as well asinjury to an operator of the tailgate, the dual-mode tailgate ispreferably prevented from operating in both of its modes simultaneously,i.e., the first and second hinge/lock assemblies are not allowed to bothbe detached from the vehicle simultaneously. This may include, forexample, enabling and disabling each of the one or more handles.Disabling of a handle often occurs by blocking movement of the handlethereby preventing the handle from opening one of the first and secondlock assemblies. Although such an arrangement has been adequate for someprior art tailgate applications, there is a need for an improved devicethat coordinates operation between the one or more handles of a dualmode tailgate and lock assemblies of the tailgate. It is additionallydesirable to be able to selectively disable the one or more handleswithout limiting ranges of motion of the handles. Still further, anyimproved device is preferably able to function without electric power.

SUMMARY

In accordance with one aspect, a tailgate synchronizer is provided forcoordinating mechanical communication between first and second handlesmounted to a tailgate in first and second lock assemblies thatselectively lock the tailgate to a vehicle body. More particularly, inaccordance with this aspect, the synchronizer includes a first lockassembly actuator lever rotatably mounted to the tailgate andselectively movable by the first handle. The first lock assemblyactuator lever is connected to the first lock assembly so that the firstlock assembly actuator lever unlocks the first lock assembly whensufficiently moved by the first handle. A second lock assembly actuatorlever is rotatably mounted to the tailgate and is selectively movable bythe second handle. The second lock assembly actuator lever is connectedto the second lock assembly so that the second lock assembly actuatorlever unlocks the second lock assembly when sufficiently moved by thesecond handle.

In accordance with another aspect, a tailgate synchronizer is providedfor selectively enabling a first handle to unlock a first lock assemblybased on the status of a second lock assembly. The first and second lockassemblies releasably locking the tailgate, to which the synchronizer ismounted, to a vehicle body. More particularly, in accordance with thisaspect, the tailgate synchronizer includes a mounting bracket fixedlysecured to the tailgate. A first lock actuator lever is pivotallymounted to the mounting bracket by a first pivot member. The first lockactuator lever is pivotally connected to a first lock rod that connectsto the first lock assembly. Movement of the first lock actuator lever ina first rotatable direction moves the first lock rod to unlock the firstlock assembly. A first handle lever is pivotally mounted to the mountingbracket by the first pivot member. The first handle lever is connectedto a first handle rod that connects to the first handle. Actuation ofthe handle causes the first handle lever to move in the first rotatabledirection. A pin is connected to the second lock assembly and isreceived through an aperture defined in the first lock actuator lever.The pin is moveable along the aperture to a first position correspondingto an unlocked position of the second lock assembly and a secondposition corresponding to a locked position of the second lock assembly.The first lock actuator lever is only moveable in the first rotatabledirection by the first handle lever when the pin is in the firstposition and the first handle lever is moved in the first rotatabledirection.

In accordance with still another aspect, a tailgate synchronizer ismounted to a tailgate for selectively allowing a first handle to unlocka first lock assembly based on the locked or unlocked condition of asecond lock assembly. The first and second lock assemblies eachreleasably lock the tailgate to a vehicle body. More particularly, inaccordance with this aspect, the tailgate synchronizer includes a firstlock actuator lever rotatably mounted to a tailgate and connected to afirst lock assembly for unlocking the first lock assembly whensufficiently moved in a first rotatable direction. A first handle leveris rotatably mounted to the tailgate and connected to first handle formoving in the first rotatable direction upon actuation of the firsthandle. The tailgate synchronizer additionally includes a means forselectively rotating the first lock actuator lever in the firstrotatable direction when the first handle lever is rotated in the firstrotatable direction.

BRIEF DESCRIPTION OF THE DRAWINGS

The one or more embodiments may take form in various components andarrangements of components, and in various steps and arrangements ofsteps. The drawings are only for purposes of illustrating the one ormore preferred embodiments and are not to be construed as limiting theinvention.

FIG. 1 is a perspective view of a vehicle having a dual-mode tailgateopenable to a first, fold-down position and, alternatively, a second,swing-open position.

FIG. 2 is a rear elevational view of the tailgate on the vehicle showinga tailgate control system (in hidden lines) for operating the tailgate.

FIG. 3 is a rear elevational view of the tailgate on the truck showingthe tailgate in the flip-open position.

FIG. 4 is a rear elevational view of the tailgate on the truck showingthe tailgate in the swing-open position.

FIG. 5 is a cross-sectional view of an upper handle assembly taken alongthe line 5-5 of FIG. 2.

FIG. 6 is a cross-sectional view of a lower handle assembly taken alongthe line 6-6 of FIG. 2.

FIG. 7 is a cross-sectional plan view of a dual-mode hinge assemblytaken along the line 7-7 of FIG. 2 showing the hinge assembly pivotallyconnecting the tailgate, shown in a closed position, to a body of thevehicle.

FIG. 8 is a partial cross-sectional side view of the dual-mode hingeassembly of FIG. 7 shown with the tailgate in the closed position.

FIG. 9 is a cross-sectional plan view of the dual-mode hinge assembly ofFIG. 7 shown with the tailgate in the swing-open position.

FIG. 10 is a cross-sectional side view of the dual-mode hinge assemblyof FIG. 7 shown with the tailgate in the flip-down position.

FIG. 11 is an exploded assembly view of the dual-mode hinge assembly ofFIG. 7.

FIG. 12 is a cross-sectional plan view of a first hinge/lock assemblytaken along the line 12-12 of FIG. 2 showing the first hinge/lockassembly releasably and hingedly connecting the tailgate, shown in aclosed position, to the vehicle body.

FIG. 13 is a cross-sectional side view of the first hinge/lock assemblytaken along the line 13-13 of FIG. 12.

FIG. 14A is a schematic view of the first hinge/lock assembly of FIG. 12shown in a latched position with the tailgate in the closed position.

FIG. 14B is a schematic view of the first hinge/lock assembly of FIG. 12shown in the latched position with the tailgate in a swing-openposition.

FIG. 14C is a schematic view of the first hinge/lock assembly of FIG. 12shown in an unlatched position with the tailgate moving toward theflip-down position.

FIG. 14D is a schematic view of the first hinge/lock assembly of FIG. 12shown in a partially latched position with the tailgate moving towardthe closed position from the flip-down position.

FIG. 15 is a cross-sectional side view of the second hinge/lock assemblytaken along the line 15-15 of FIG. 2 showing the second hinge/lockassembly releasably and hingedly connecting the tailgate, shown in aclosed position, to the vehicle body.

FIG. 16 is a cross-sectional rear view of the second hinge/lock assemblytaken along the line 16-16 of FIG. 15 showing the second hinge/lockassembly in a latched position with the tailgate in the closed position.

FIG. 17 is a cross-sectional side view of the second hinge/lock assemblyof FIG. 15 shown in the latched position with the tailgate in theflip-down position.

FIG. 18 is a cross-sectional plan view of the second hinge/lock assemblyof FIG. 15 shown in an unlatched position with the tailgate movingtoward the swing-open position.

FIG. 19A is schematic side view of the second hinge/lock assembly ofFIG. 15 shown in the unlatched position with the tailgate moving towardthe swing-open position.

FIG. 19B is a schematic rear view of the second hinge/lock assembly ofFIG. 15 shown with a sensor rod mechanically communicating the unlatchedposition of the second hinge/lock assembly.

FIG. 20A is a schematic side view of the second hinge/lock assembly ofFIG. 15 shown in the latched position with the tailgate in the closedposition.

FIG. 20B is a schematic rear view of the second hinge/lock assembly ofFIG. 15 shown with the sensor rod mechanically communicating the latchedposition of the second hinge/lock assembly.

FIG. 21 is a side cross-sectional view of a locking assembly taken alongthe line 21-21 of FIG. 2 showing the locking assembly releasablyconnecting the tailgate, shown in a closed position, to the vehiclebody.

FIG. 22 is a rear cross-sectional view of the locking assembly takenalong the line 22-22 of FIG. 21.

FIG. 23A is a schematic side view of the locking assembly of FIG. 21shown in an unlatched position.

FIG. 23B is a schematic rear view of the locking assembly of FIG. 21showing an actuator rod moved to unlatch the locking assembly from thevehicle body.

FIG. 24 is a rear elevational view of a synchronizer controllingmechanical communication between the handle assemblies, the hinge/lockassemblies and the locking assembly.

FIG. 25 is a cross-sectional view of the synchronizer taken along theline 25-25 of FIG. 24.

FIG. 26 is a cross-sectional view of the synchronizer taken along theline 26-26 of FIG. 24.

FIG. 27 is a front elevational view of the synchronizer of FIG. 24 shownwith the tailgate in the closed position.

FIG. 28 is a schematic front view of the synchronizer of FIG. 24 shownwith the tailgate in the flip-down position.

FIG. 29 is a schematic front view of the synchronizer of FIG. 24 shownwith the tailgate in the swing-open position.

FIG. 30 is a schematic front view of the synchronizer of FIG. 24 shownwith the tailgate in the closed position and both handles being pulledsimultaneously.

FIG. 31 is a schematic front view of the synchronizer of FIG. 24 shownwith the second hinge/lock assembly unlatched and the upper handle beingpulled.

FIG. 32 is a schematic front view of the synchronizer of FIG. 24 shownwith the first hinge/lock assembly unlatched and the lower handle beingpulled.

FIG. 33 is a schematic front view of the synchronizer of FIG. 24 shownwith the sensor rods 80,92 broken and both the upper and lower handlesbeing pulled.

DETAILED DESCRIPTION

Referring now to the drawings wherein the showings are for purposes ofillustrating one or more embodiments only and not for purposes oflimiting the same, with reference to FIG. 1, a closure structure orassembly, such as dual-mode tailgate 10, is shown as a component of aload-carrying bed 12 of a vehicle V. In the illustrated embodiment, thevehicle is a sport utility truck (SUT), but it is to be appreciated bythose skilled in the art that the vehicle V could be any other type ofvehicle having a bed, such as a pick-up truck, utility truck or othervehicle. Generally, the bed 12 includes a bed floor 14 having aplurality of walls 16,18,20 extending upwardly adjacent three edgesthereof and forming a portion of a vehicle body of the vehicle V.

The dual-mode or dual-axis tailgate 10 is positioned along an open, rearedge 28 of the bed floor 14. More particularly, the tailgate 10 extendsbetween the first and second sidewalls 16,20 to selectively close anopen end of the load-carrying bed 12. The tailgate 10 is mounted to thevehicle V and is able to pivot about a first axis 30 (FIG. 2) formovement between a closed position and a fold-open position (FIG. 3). Inthe illustrated embodiment, the first axis 30 is generally horizontaland parallel with the rear edge 28 of the bed floor 14 which defines theopening in which the tailgate 10 is disposed. The tailgate 10 is alsoalternatively able to pivot about a second axis 34 (FIG. 2) for movementbetween the closed position and a swing-open position (FIG. 4). In theillustrated embodiment, the second axis 34 is generally vertical andparallel with a first sidewall end 38 which also defines the opening inwhich the tailgate 10 is disposed. The second axis 34 is generallynormal relative to the first axis.

To facilitate the dual-mode action of the tailgate 10, with additionalreference to FIGS. 2-4, a dual-mode hinge assembly 40 attaches or ismounted to the tailgate 10 at or adjacent a first corner of the tailgateformed at the intersection of the bottom edge 32 and a first lateraledge 36 of the tailgate 10. The dual-mode hinge assembly 40 pivotallyconnects the tailgate 10, along the first and second axes 30,34, to thevehicle V. More specifically, the dual-mode hinge assembly 40 pivotallyconnects to a flange or pillar 42 extending from and connected to thefirst sidewall end 38 adjacent the rear edge 28 of the bed floor 14 formovement about the first axis 30 and alternative movement about thesecond axis 34. In one embodiment, the dual-mode hinge assembly is thesame or similar to that described in commonly owned, U.S. patentapplication Ser. No. 10/663,581, entitled “Tailgate Dual Mode Hinge WithIntegrated Checker” and filed on Sep. 16, 2003, expressly incorporatedherein by reference.

A first hinge/lock assembly 44 attaches or is mounted to the tailgate 10spaced from the hinge assembly 40 in a first direction. Morespecifically, the hinge/lock assembly 44 is mounted at or adjacent asecond corner of the tailgate formed at the intersection of the firstlateral edge 36 and a top edge 46 of the tailgate (upper left corner inFIG. 2). The first hinge/lock assembly 44, also referred to herein as afirst lock assembly, selectively latches or locks to a first hinge/lockstriker 48 to releasably lock the tailgate 10 to the vehicle V. Thefirst hinge/lock striker is mounted to the pillar 42 above the hingeassembly 40. With additional reference to FIG. 4, when operating as ahinge, the first hinge/lock assembly 44 cooperates with the hingeassembly 40 to pivotally support the tailgate 10 along or about thesecond axis 34 and allows the tailgate to move between the tailgateclosed position and the swing-open position.

A second hinge/lock assembly 50 attaches or is mounted to the tailgate10 spaced from the hinge assembly 40 in a second direction. Morespecifically, the hinge/lock assembly 50 is mounted at or adjacent athird corner of the tailgate formed at the intersection of the bottomedge 32 and a second lateral edge 52 of the tailgate (lower right cornerin FIG. 2). The second hinge/lock assembly 50, also referred to hereinas a second lock assembly, selectively latches or locks to a secondhinge/lock striker 54 (FIG. 4) to releasably locking the tailgate 10 tothe vehicle V. The striker 54 is mounted to a flange or pillar 56extending from and connected to a second sidewall end 58 adjacent therear edge 28 of the bed floor 14. With additional reference to FIG. 3,the second hinge/lock assembly 50 cooperates with the hinge assembly 40to pivotally support the tailgate 10 along or about the first axis 30and allows the tailgate to move between the tailgate closed position andthe fold-open or flip-down position. A support cable 60 is optionallyprovided for supporting the tailgate 10 in the flip-down position. Thesupport cable 60 connects to the flange 42 adjacent the first striker 48and to the first lateral edge 36 of the tailgate 10.

A locking assembly 62, also referred to herein as a third lock assembly,attaches or is mounted to the tailgate 10 at or adjacent a fourth cornerof the tailgate formed at the intersection of the top edge 46 and thesecond lateral edge 52 of the tailgate (upper right corner in FIG. 2).The locking assembly 62 selectively latches to a locking striker 64 toreleasably lock the tailgate to the vehicle V. The striker 64 is mountedto the flange 56 above the second hinge/lock striker 54. The tailgate 10is openable toward or to the fold-open position about the axis 30 whenboth the first hinge/lock assembly 44 is unlatched from the firsthinge/lock striker 48 and the locking assembly 62 is unlatched from thelocking striker 64. The tailgate 10 is openable toward or to theswing-open position about the axis 34 when both the second hinge/lockassembly 50 is unlatched from the second hinge/lock striker 54 and thelocking assembly 62 is unlatched from the locking striker 64.

The tailgate 10 additionally includes a first or upper handle assembly70 and a second or lower handle assembly 72. The first or upper handleassembly 70 is centrally mounted to the tailgate 10 for opening thereofin the flip-down mode. The second or lower handle assembly 72 is mountedadjacent the bottom edge 32 of the tailgate 10 for opening thereof in aswing-open mode. A tailgate synchronizer 74 is mounted within thetailgate 10 for mechanically communicating and coordinating operationbetween the handle assemblies 70,72, the first and second hinge/lockassemblies 44,50 and the locking assembly 62. The synchronizer 74functions without the use of electrical power enabling the tailgate 10to be operational even when electrical power is unavailable, such asmight occur as the result of a dead battery.

More specifically, as will be described in more detail below, the upperhandle assembly 70 communicates with a synchronizer 74 through a rod 76and the lower handle assembly 72 communicates with the synchronizer 74through a cable 78 (rod 76 and cable 78 shown schematically in FIG. 2).The synchronizer 74 selectively allows a handle 80 of the upper handleassembly 70 to unlock the hinge/lock and locking assemblies 44,62 fromtheir respective strikers 48,64 when the upper handle 80 is pulled oractuated via rods 82,84 (shown schematically in FIG. 2). Thesynchronizer 74 also selectively allows a handle 86 of the lower handleassembly 72 to unlock the hinge/lock and locking assemblies 50,62 fromtheir respective strikers 54,64 when the lower handle 86 is pulled oractuated via the rod 84 and an actuator rod 88 (shown schematically inFIG. 2).

To prevent damage to the vehicle V and/or the tailgate 10, as well aspotential injury to a user of the tailgate, the tailgate 10 is preventedfrom operating in both of its modes (swing-open and fold-down)simultaneously. If the tailgate 10 was able to open in both modessimultaneously, the tailgate would only be connected to the vehicle V bythe hinge assembly 40, as all three lock assemblies 44,50,62 would beunlocked. For this purpose, the synchronizer 74 additionallycommunicates with the first and second hinge/lock assemblies 44,50through sensor rods 90,92 (shown schematically in FIG. 2). Based on thecommunications received from the rods 90,92, the synchronizer 74selectively enables communication between the handle assemblies 70,72and each of the first hinge/lock assembly 44, the second hinge/lockassembly 50, and the locking assembly 62.

Specifically, the second hinge/lock assembly 50 is prevented fromunlatching from its striker 54 whenever the first hinge/lock assembly 44is already unlatched from its striker 48. Similarly, the firsthinge/lock assembly 44 is prevented from unlatching from its striker 48whenever the second hinge/lock assembly 50 is already unlatched from itsstriker 54. Moreover, the first and second hinge/lock assemblies 44,50are prevented from both unlatching from their respective strikers 48,54at the same time. Thus, one of the first and second hinge/lockassemblies 44,50 is always latched onto its striker 48 or 54 wheneverthe other of the first and second hinge/lock assemblies is unlatchedfrom its striker.

With reference to FIG. 5, the handle 80 of the upper handle assembly 70mechanically communicates with the synchronizer 74 through the rod 76.Specifically, the handle 80 is mounted within a recess 96 provided in anexterior side of the tailgate 10. The handle 80 engages or is fixedlyconnected to a first arm 98 of an S-shaped lever 100 that is pivotallymounted to the tailgate 10 at hinge 102. A hinged connection 104connects a second arm 106 of the lever 100 to the rod 76. A centerportion 108 of the lever 100 connects the first arm 98 to the second arm106. As shown, when the handle 80 is pulled, the lever 100 is pivotallymoved which lowers arm 106 of the lever. Lowering of the arm 106 causesthe rod 76 to move in the direction of arrow 466 and generally in thedirection of the synchronizer 74. Thus, the stroke of the handle 80,when pulled, is communicated to the synchronizer 74 by the rod 76 movingor advancing toward the synchronizer.

With reference to FIG. 6, the handle 86 of the lower handle assembly 72mechanically communicates with the synchronizer 74 through the cable 78.Specifically, the handle 86 is mounted adjacent the bottom edge 32 ofthe tailgate 10. A recessed area 110 is formed along a portion of thebottom edge 32 and the handle 86 is mounted therein. The handle 86engages or is fixedly connected to a first arm 112 of a lever 114 thatis pivotally mounted to the tailgate 10 at hinge 116. An end of thecable 78 is attached to a second arm 118 of the lever 114. A cable mount120 that allows the cable 78 to slidably move therethrough can beprovided for guiding the cable 78 adjacent the handle assembly 72.Rotation of the second arm 118 causes the cable 78 to be pulled. Thus,the stroke of the handle 86, when pulled, is communicated to thesynchronizer 74 by the cable 78 pulling in the direction of arrow 490from the synchronizer 74.

With reference to FIGS. 7-11, in accordance with the illustratedembodiment, the dual-mode hinge assembly 40 includes a body bracket 130that fixedly mounts to the pillar 42. The bracket 130 includes a baseportion 132 and a pair of spaced apart legs 134,136 extending from thebase portion. The legs 134,136 are generally the same or similar andextend from the base portion 132 in a direction approximately normalrelative thereto. The bracket 132 further includes a plurality ofmounting holes 138 defined in the base portion 132 that receive mountingbolts 140 for securing the bracket 130 to the pillar 42 of the vehicleV.

The hinge assembly 40 further includes a tailgate bracket 142 thatfixedly mounts to the tailgate 10 adjacent a first corner thereof. Thebracket 142 includes a mounting portion 144 defining a plurality ofmounting holes 146 that receive bolts 148 for securing the bracket 142to the tailgate 10. Specifically, the mounting portion 144 is connectedto a frame portion 150 of the tailgate. In one embodiment, the tailgate10 includes the frame portion 150 formed of stamped sheet metal to whicha skin 152 and cladding 154 are attached. The skin 152 can be made togenerally match an exterior of the vehicle V and the inner cladding 154can be stiffened to accept loading thereon when the tailgate 10 is inthe flip-down position. For example, the tailgate structure can be thesame or similar to the tailgate described in commonly owned, U.S. patentapplication Ser. No. 10/663,183, entitled “Improved Frame Structure forVehicle Tailgate” and filed on Sep. 16, 2003, expressly incorporatedherein by reference. The bracket 142 additionally includes a hingeportion 156 having a base 158 generally parallel to the mounting portion144 and legs 160,162 extending from the base 158 in a directionapproximately normal relative thereto.

The hinge assembly 40 further includes a rotatable member 168 pivotallyconnected to the body bracket 130 for rotation about the first axis 30and pivotally connected to the tailgate bracket 142 for rotation of thetailgate bracket 142 and tailgate 10 about the second axis 34. Morespecifically, a first pivot pin or pintle 170 rotatably connects therotatable member 168 to the body bracket 130. The rotatable member 168defines a first throughhole 172 that is aligned with throughholes174,176 defined, respectively, in legs 134,136. The pin 170 is receivedthrough the aligned throughholes 172,174,176 to rotatable connect therotatable member 168 to the bracket 130 along the first axis 30.

The pin 170 includes heads 178 at both ends thereof for securing the pinbetween the legs 134,136. One of the heads is formed in the pin prior toassembly and the other is formed by riveting during assembly.Optionally, bearings 180 can be employed radially between the pin 170and the rotatable member 168. The horizontal pin 170 allows therotatable member 168, the tailgate bracket 142 and the tailgate 10connected thereto to rotate relative to the body bracket 130 and thevehicle V which remain stationary during pivoting of the tailgate 10about the first axis 30.

A vertical pivot pin or pintle 182 rotatably connects the rotatablemember 168 to the tailgate bracket 142. The vertical pin 182 is receivedin a second throughhole 184 defined in the rotatable member and a pairof aligned throughholes 186,188 defined, respectively, in the legs160,162. Like the horizontal pin 178, the vertical pin 182 includesheads 178 at both ends thereof to secure the pin 182 between the legs160,162. Again, optionally, bearings 180 can be employed radiallybetween the pin 182 and the rotatable member 168. The pin 182 allows thetailgate bracket 142 and the tailgate 10 connected thereto to rotaterelative to the rotatable member 168, the body bracket 130 and thevehicle V during pivoting of the tailgate about the second axis 34.

The rotatable connections between the rotatable member 168 and thebrackets 130,142 are described according to one embodiment of theinvention. These types of rotatable connections employed in hinges aregenerally longer lasting, easier to manufacture and easier to installthan other types of rotatable connections. However, it is contemplatedthat other rotatable connections, such as, for example, ballbearing-type rotatable connections, could be used and are to beconsidered within the scope of the present invention.

The rotatable member 168 includes a body portion 190 and an arm portion192 extending from the body portion 190. The throughhole 184 extendsthrough the body portion 190 along a longitudinal extent thereof. Thethroughhole 172 extends through the body portion 190 in an orientationgenerally normal to an axis defined along the throughhole 184 and offsetfrom throughhole 184 such that the throughholes 172,184 do notintersect. The arm portion 192 extends in a direction generallyperpendicular to axes defined along both throughholes 172,184 andattaches to the body portion 190 along a longitudinal extent of the bodyportion 190 and generally adjacent the throughhole 172.

A cam profile plate 194 is mounted to the upper leg 160 by rivets 196received in throughholes 198 defined in the upper leg. The plate 194includes a cam surface or edge 200 having indexed or checker locations202 defined therein. For engagement with the cam surface 200, as will bedescribed in more detail below, a biasing member 204 is fixedly securedto the rotatable member 168. More particularly, the biasing member 204is a C-shaped torsion spring having an elongated portion 206, a firstcurved portion 208 with a short portion 210 extending therefrom in anorientation parallel to the elongated portion 206 and a second curvedportion 212 with another short portion 214 extending therefrom in anorientation parallel to the elongated portion 206.

The elongated portion 206 is received within a circular groove 216defined in one side of the rotatable member arm portion 192. Optionally,a semicircular bearing or sleeve 218 can be received in the groove 216for directly engaging the torsion spring 204. A securing plate 220 ismounted to the rotatable member arm portion 192 to secure the torsionspring 204 in the groove 216. In the illustrated embodiment, thesecuring plate 220 includes a first portion 222 that mounts against oradjacent the torsion spring 204 and a mounting portion 224 that isreceived in a corresponding or mating groove 226 defined in the armportion 192 adjacent the groove 216. Additionally, rivets 228 arereceived in throughholes 230,232 defined in the plate 220 and therotatable member arm portion 192. Optionally, a gasket 234 can bereceived between the securing plate 220 and the rotatable member 168with the spring 204 received in the groove 216 thereof.

The short portion 210 of the spring 204 is positioned to be engaged bythe cam surface 200 of the plate 194 when the tailgate 10 is opened toand/or closed from the swing-open position, i.e., about the first pivotaxis 30. More specifically, the short portion 210 includes a camfollower 236 rotatable attached thereto having a generally roundcross-section. The follower 236 is positioned on the short portion 210so that it is engaged by cam surface 200 as the tailgate opens toward orfrom the swing-open position. In the illustrated embodiment, the camsurface 200 is generally parallel with the first vertical axis 30.

The follower 236 includes radial flanges 238 for maintaining alignmentof the cam surface 200 with the follower 236. The engagement between thefollower 236 and the cam surface 200 having checker locations 202provides an integrated checker function to the hinge assembly 40 whenused for pivotally opening the tailgate 10 about the first axis 30. Asshould be appreciated by those skilled in the art, the cam surface 200can be shaped such that engagement with the follower 236 of the torsionspring 204 (1) urges the tailgate 10 into specific predetermined orpreselected positions or checkpoints when the tailgate 10 isopened/closed about the first pivot axis 30, (2) maintains the tailgate10 in one of said specific predetermined positions until a predeterminedforce is applied to the tailgate 10 to overcome the urging of thetorsion spring 204 and/or (3) limits rapid or fast opening and closingof the tailgate 10 about the first pivot axis 30. It should additionallybe appreciated that other specific checker arrangements other than theillustrated embodiment can be utilized and all such arrangements are tobe considered within the scope of the present invention.

The dual mode hinge assembly 40 described herein can be assembled withcomponents that are relatively easy and inexpensive to manufacture andassemble. For example, the components of the hinge assembly 40 caninclude primarily stamped and/or welded components. Further, the use ofbolts 140,148 for, respectively, connecting the body bracket 130 to thevehicle V and for connecting the tailgate bracket 142 to the tailgate 10enables relatively easy assembly of the tailgate to an associatedvehicle. This, in contrast to all or most prior art tailgates, allowsthe tailgate to be assembled separately from the vehicle and attached tothe vehicle after both the tailgate and the vehicle have already beensubassembled.

With reference to FIGS. 12 and 13, the first hinge/lock assembly 44includes a latching assembly having a lock body 250 and a latch 252. Thelock body 250 is secured to the tailgate 10 and, more specifically, thetailgate frame 150 via conventional fasteners, such as rivets or bolts254, so that a lock body recess 256 defined in the lock body is alignedwith and able to receive the striker 48 when the tailgate 10 is in theclosed position. The lock body 250 generally includes a first wall 250a, a second wall 250 b spaced from the first wall and at least oneconnecting wall 250 c extending between the first and second walls. Therecess 256 is provided through the at least one connecting wall 250 cand into portions of the walls 250 a, 250 b.

In the illustrated embodiment, the striker 48 is rotatably mountedbetween spaced apart arms 258,260 of a striker mounting bracket 262. Thebracket 262 is mounted to the pillar 42 of the vehicle V viaconventional fasteners, such as rivets or bolts 264. The bracket 262includes support portions 266,268 for strengthening the arms 258,260. Inthe illustrated embodiment, the support cable 60 is connected to thelower support portion 268. In one embodiment, the striker 48 includes ahead 270 limiting axial movement of the striker relative to the arms258,260. Bearings 272,274 are provided radially between the striker 48and portions of the arms 258,260 into which throughholes are defined forreceiving the striker. A retaining ring 276 is used to further limitaxial movement of the striker 48 on an end thereof opposite the head270.

When the tailgate 10 is in the closed position, the striker 48 isreceived in the recess 256. A bumper 278 of a resilient material, suchas rubber, can be provided within the recess 256 for cushioning ordampening engagement between the striker 48 and the lock body 250,particularly when the striker 48 is first received into the recess 256after the tailgate 10 is moved to the closed position from the flip-downposition. The latch 252 is rotatably mounted to the lock body 250 forselectively latching onto the striker 48 to lock the striker to the lockbody 250 and in the lock body recess 256 thereby locking the firsthinge/lock assembly 44 to the striker 48 and the pillar 42 of thevehicle V. The latch 252 includes a latch recess 280 for receiving thestriker 48 and is moveable between a latched position and an unlatchedposition. More particularly, as will be described in more detail below,when the tailgate 10 is moved to the closed position from the flip-downposition and the striker 48 is received in the recesses 256,280, thestriker 48 causes the latch 252 to move and, specifically, rotate aboutthe striker 48 to the latched position (shown in FIG. 12) wherein thelatch locks the striker 48 in the lock body recess 256 of the lock body250. When the latch 252 is in the unlatched position (shown in FIG.14C), the striker 48 is freely moveable into and from (i.e., removable)the recesses 256,280.

The hinge/lock assembly 44 additionally includes a latch biasing means,such as torsion spring 282, rotatably urging the latch 252 in a firstrotatable direction (clockwise in FIG. 12) toward the unlatchedposition. A ratchet 284 is rotatably mounted to the lock body 250adjacent the latch 252 for selectively engaging or locking the latch 252and holding the latch in the latched position. More particularly, thelatch 252 includes a catch surface 252 a that is selectively engaged byan opposing catch surface 284 a defined on a first leg 284 b of theratchet. A ratchet biasing means, such as torsion spring 286, rotatablyurges the ratchet 284 in a second rotatable direction (counterclockwisein FIG. 12) toward an engaged or engaging position, wherein the opposingcatch surface 284 a is urged into engagement with the latch 252.

The ratchet 284 is moveable between the engaged position wherein theratchet locks the latch in the latched position and a disengagedposition wherein the latch is moveable between the latched position andthe unlatched position. As will be described in more detail below, alocked or unlocked status or condition of the striker 48 in the lockbody recess 256 is determinable by the position (engaged or disengaged)of the ratchet. The ratchet 284 includes an extending portion 284 c thatengages a stop 288 to limit movement of the ratchet in the secondrotatable direction. The stop 288 also limits movement of the latch 252in the first rotatable direction when the ratchet 284 is in thedisengaged position that allows movement of the latch between thelatched position and the unlatched position.

A second leg 284 d of the ratchet includes a pin 284 e extendingtherefrom and positioned for engagement with a pair of rotatably mountedlevers, including actuator lever 290 and sensor lever 292. The actuatorlever 290 is rotatably mounted to the lock body 250 and has a first leg290 a positioned adjacent the pin 284 e for engagement therewith and asecond leg 290 b pivotally connected to the actuator rod 82 therebyrotatably connecting the actuator rod 82 to the lock body 250.Similarly, the sensor lever 292 is rotatably mounted to the lock body250 and has a first leg 292 a positioned adjacent the pin 284 e forengagement therewith and a second leg 292 b pivotally connected to thesensor rod 90 thereby rotatably connecting the sensor rod 90 to the lockbody 250. In the illustrated embodiment, the first leg 292 a defines aslot 292 c that receives the pin 284 e so that the sensor lever 292 isadapted for corresponding movement with the ratchet 284. Alternatively,the first leg 292 a could be configured without a slot and positioned onan opposite side of the pin 284 e than the leg 290 a. In such analternative arrangement, a biasing means, such as torsion spring, couldbe provided to rotatably urge the sensor lever 292 in the firstrotatable direction to maintain engagement between the leg 292 a and thepin 284 e which would ensure that the position of the lever 292corresponds with the position of the ratchet 284.

With reference to FIG. 14A, the tailgate 10 is shown in the closedposition and the first hinge/lock assembly 44 is shown in a latched orlocked position. In these positions, the striker 48 is received in thelock body recess 256 and the latch 252 is in the latched positionthereby locking the striker within the recess 256 and releasablyconnecting the striker 48 to the lock body 250, which also releasablyconnects the vehicle body to which the striker 48 is mounted to thetailgate 10 to which the lock body 250 is mounted. Though the latch 252is urged toward the unlatched position, the latch is held in the latchedposition by the ratchet 284 which is in the engaged position. Theratchet 284 is in the engaged position when locking the latch 252 in thelatched position to lock the striker 48 in the lock body recess 256.Particularly, the opposing catch surface 284 a of the ratchet engagesthe catch surface 252 a of the latch to maintain the latch in thelatched position when the ratchet is in the engaged position.

With the ratchet 284 in the engaged position, the pin 284 e causes thesensor lever 292 to rotate in the first direction toward a sensor leverfirst position that corresponds with the latched position of the latch252 and the engaged position of the ratchet 284. In the sensor leverfirst position, the sensor rod 90 is moved toward or in the direction ofthe synchronizer 74, as shown by arrow 508, to a sensor rod firstposition corresponding to the ratchet engaged position. With additionalreference to FIG. 14B, when the striker 48 is locked to the lock body250, the tailgate 10 is movable toward or to the swing-open position.While opening toward the swing-open position, the lock body 250 pivotsabout the striker 48 and the latch 252 remains in the latched positionto retain the striker 48 within the lock body recess 256. Likewise, theratchet 284 remains in the engaged position and the sensor lever 292remains in the sensor lever first position wherein the sensor rod 90mechanically communicates with the synchronizer 74 by the rod 90 beingin a forward position in the direction of arrow 508.

To unlock the first hinge/lock assembly 44 from the striker 48, withadditional reference to FIG. 14C, the synchronizer 74 pulls the actuatorrod 82 in a first direction, indicated by arrow 472, which rotates theactuator lever 290 in the second rotatable direction. The leg 290 aengages and moves the pin 284 e to rotate the ratchet 284 in the firstrotatable direction. Movement of the pin 284 e causes the pin to engagethe leg 292 a of the sensor lever 292 thereby moving the sensor lever292 in the second rotatable direction to a sensor lever second positioncorresponding to the ratchet disengaged position wherein the sensor rod90 mechanically communicates with the synchronizer 74 by the rod 90being in a retracted position, indicated by arrow 478.

The ratchet 284 is moved in the first rotatable position against theurging of the spring 286 to the disengaged position wherein the opposingcatch surface 284 a is removed as an obstruction to the latch 252. Withthe ratchet 284 in the disengaged position, the spring 282 moves thelatch 252 to the unlatched position which unlocks the first hinge/lockassembly 44 and allows removal of the striker 48 from the lock bodyrecess 256. More particularly, as the latch 252 moves toward theunlatched position, the latch 252 forcibly moves the striker 48 from thelock body recess 256 which causes the tailgate 10 to at least partiallymove toward the flip-down position (as shown in FIG. 14C). The stop 288limits movement of the latch 252 in the first rotatable direction byengaging a first leg 252 b of the latch. Thus, the stop 288 holds thelatch 252 in the unlatched position.

As long as the ratchet 284 remains in the disengaged position, thesensor lever 292 remains in the sensor lever second position and the rod90 remains in the retracted position. Thus, when the ratchet 284 is inthe disengaged position, the sensor rod 90 continues to mechanicallycommunicate to the synchronizer 74 that the hinge/lock assembly 44 isunlocked by remaining in the retracted position. Until the latch 252 isre-latched onto the striker 48, the ratchet 284, due to its profile orshape, remains in the disengaged position. Thus, the ratchet 284 remainsin the disengaged position when the latch is in the unlatched positionand/or the latch is moveable between the latched position and theunlatched position. The ratchet 284 is only in the engaged position whenthe latch is in the latched position. More particularly, with additionalreference to FIG. 14D, when the striker 48 is initially received ormoved in the lock body recess 256 and the latch recess 280 causing thestriker to partially rotate the latch in the second rotatable directionagainst the urging of the spring 282 toward the latched position, theratchet 284 remains in the disengaged position.

The spring 286 urges the ratchet 284 and, more particularly, the leg 284b into the latch 252, but, until the latch is rotated to the latchedposition (shown in FIG. 14A), the opposing catch surface 284 a of theratchet does not engage the catch surface 252 a of the latch. When thecatch surface 252 a finally passes the opposing catch surface 284 a(i.e., the latch 252 is in the latched position), the ratchet 284 movesinto the engaged position to hold the latch in the latched position.When the ratchet 284 is in the engaged position, the pin 284 e rotatesthe sensor lever 292 back to the first sensor lever position wherein thesensor rod 90 is moved back to the forward position mechanicallycommunicating the locked status of the first hinge/lock assembly 44.

Thus, the hinge/lock assembly 44 and, particularly, the shape of theratchet 284 employed in the hinge/lock assembly 44, enable the ratchet284 to be used for communicating the status of the hinge/lock assembly44, locked or unlocked. The shape of the ratchet 284 and theconfiguration of the lock body 250 allow the ratchet's position todirectly correspond to the status of the hinge/lock assembly 44. Whenthe striker 48 is locked to the lock body 250 by the latch 252, theratchet is in the engaged position. When the striker 48 is unlocked fromthe lock body 250, the ratchet is in the disengaged position and remainsthere until the lock body 250 is re-locked to the striker 48. The lever292 and rod 90 communicate the position of the ratchet, and thereby thestatus of the hinge/lock assembly 44, to the synchronizer 74.

With reference to FIGS. 15-18, the second hinge/lock assembly 50includes a latching assembly having a lock body 302 and a latch 304. Thelock body 302 is secured to the tailgate 10 and, more specifically, thetailgate frame 150 via conventional fasteners, such as rivets or bolts306, so that a lock body recess 308 defined in the lock body is alignedwith and able to receive the striker 54 when the tailgate 10 is in theclosed position (shown in FIG. 15). The lock body 302 generally includesa first wall 302 a, a second wall 302 b spaced from the first wall andat least one connecting wall 302 c extending between the first andsecond walls. The recess 308 is provided through the at least oneconnecting wall 302 c and into portions of the walls 302 a, 302 b.

In the illustrated embodiment, the striker 54 is rotatably mountedbetween spaced apart arms 310,312 of a striker mounting bracket 314. Thebracket 314 is mounted to the pillar 56 of the vehicle V viaconventional fasteners, such as bolts 316. In most respects, accordingto the illustrated embodiment, the striker 54 is like the striker 48.For example, the striker 54 includes a head 318, bearings 320,322provided annularly about the striker 54, and a retaining ring 324. Whenthe tailgate 10 is in the closed position, the striker 54 is received inthe recess 308. A bumper 326, like bumper 278, can be provided withinthe recess 308.

The latch 304 is rotatably mounted to the lock body 302 for selectivelylatching onto the striker 54 to lock the striker to the lock body 302and in the lock body recess 308 thereby locking the second hinge/lockassembly 50 to the striker 54 and the pillar 56 of the vehicle V. Thelatch 304 includes a latch recess 328 for receiving the striker 54 andis moveable between a latched position and an unlatched position. Moreparticularly, as will be described in more detail below, when thetailgate is moved to the closed position from the swing-open position(shown between swing-open position and closed position in FIG. 18) andthe striker 54 is received in the recesses 308,328, the striker 54causes the latch 304 to move and, specifically, rotate about the striker54 to the latched position (shown in FIG. 15) wherein the latch locksthe striker 54 in the lock body recess 308 of the lock body 302. Whenthe latch 304 is in the unlatched position (shown in FIG. 19A), thestriker 54 is freely moveable (i.e., removable) into and from therecesses 308,328.

The second hinge/lock assembly 50 additionally includes a latch biasingmeans, such as torsion spring 330, rotatably urging the latch 304 in thesecond rotatable direction (counterclockwise in FIG. 15) toward theunlatched position. A ratchet 332 is rotatably mounted to the lock body302 adjacent the latch 304 for selectively engaging or locking the latch304 and holding the latch in the latched position. More particularly,the latch 304 includes a catch surface 304 a that is selectively engagedby an opposing catch surface 332 a defined on a first leg 332 b of theratchet. A ratchet biasing means, such as torsion spring 334, rotatablyurges the ratchet 332 in the first rotatable direction (clockwise inFIG. 15) toward an engaged or engaging position, wherein the opposingcatch surface 332 a is urged into engagement with the latch 304. Theratchet 332 is moveable between the engaged position wherein the ratchetlocks the latch 304 in the latched position and a disengaged positionwherein the latch is moveable between the latched position and theunlatched position. As will be described in more detail below, a lockedor unlocked status of the striker 48 in the lock body recess 256 isdeterminable by the position (engaged or disengaged) of the ratchet. Theratchet 332, which is substantially similar in shape to the ratchet 284of the first hinge/lock assembly, includes an extending portion 332 cthat engages a stop 336 to limit movement of the ratchet in the firstrotatable direction. The stop 336 also limits movement of the latch 304in the second rotatable direction when the ratchet 332 is in thedisengaged position that allows movement of the latch between thelatched position and the unlatched position.

A second leg 332 d of the ratchet includes a pin 332 e extendingtherefrom and positioned for engagement with a rotatably mountedconnecting lever 338. More particularly, the pin 332 e is received in arecess 338 a defined in a first leg 338 b of the connecting lever. Thelever 338 includes a second leg 338 c positioned for engagement with apair of levers, including actuator lever 342 and sensor lever 344, whichare rotatably mounted and oriented approximately normal relative to theconnecting lever 338. More particularly, the connecting lever 338rotates about an axis approximately parallel relative to the first axisand the levers 342,344 are positioned to be approximately parallel withthe opening or a plane in which the tailgate 10 is disposed. The lever338 also includes a hook portion 338 d positioned on an opposite side ofthe sensor lever 344 than the second leg 338 c. The hook portion 338 dand the second leg 338 c together form a C-shaped portion of the lever338 that defines a recess 338 e in which the sensor lever 344 isdisposed. The capture of the lever 344 within the C-shaped portion 338c, 338 d causes the sensor lever 344 to move with the lever 338.

The actuator lever 342 includes a first leg 342 a positioned adjacentthe second leg 338 c for engagement with lever 338. The lever 342additionally includes a second leg 342 b pivotally connected to theactuator rod 88. The sensor lever 344 includes a first leg 344 apositioned adjacent the second leg 338 c for engagement therewith andwithin the recess 338 e and a second leg 344 b pivotally connected tothe sensor rod 92. As shown, in the illustrated embodiment, theconnector lever second leg 338 c is disposed between the legs 342 a, 344a. Optionally, fold-over portions 346 are provided on the legs 342 a,344 a of the levers for cushioning the engagement between the leg 338 cand the levers 342,344. The sensor lever 344 is rotatably urged in thefirst rotatable direction into engagement with the connecting lever 338by spring 456 (FIG. 27) acting through the sensor rod 92.

With specific reference to FIGS. 15 and 16, the tailgate is shown in theclosed position and the second hinge/lock assembly 50 is shown in alatched or locked position. In these positions, the striker 54 isreceived in the lock body recess 308 and the latch 304 is in the latchedposition thereby locking the striker within the recess 308 andreleasably connecting the striker 54 to the lock body 302, which alsoreleasably connects the vehicle body to which the striker 54 is mountedto the tailgate 10 to which the lock body 302 is mounted. The latch 304is urged toward the unlatched position, but is held in the latchedposition by the ratchet 332 which is in the engaged position. Theratchet 332 is in the engaged position when locking the latch 304 in thelatched position to lock the striker 54 in the lock body recess 308.Specifically, the opposing catch surface 332 a of the ratchet engagesthe catch surface 304 a of the latch to maintain the latch in thelatched position when the ratchet is in the engaged position.

When the ratchet 332 in the engaged position, the pin 332 e causes theconnecting lever 338 to rotate in the second rotatable direction so thatthe connecting lever second leg 338 c and hook portion 338 d rotate thesensor lever 344 in the first rotatable direction to a sensor leverfirst position that corresponds with the latched position of the latch304 and the engaged position of the ratchet 332. In the sensor leverfirst position, the sensor rod 92 is moved toward or in the direction ofthe synchronizer 74, as shown by arrow 510, to a sensor rod firstposition corresponding to the ratchet engaged position. With referenceto FIG. 17, when the striker 54 is locked to the lock body 302, thetailgate 10 is movable toward or to the fold-down position. Whileopening toward the fold-down position, the lock body 302 pivots aboutthe striker 54 and the latch 304 remains in the latched position toretain the striker 54 within the lock body recess 308. Likewise, theratchet 332 remains in the engaged position and the sensor lever 344remains in the sensor lever first position wherein the sensor rod 92mechanically communicates with the synchronizer 74 by the rod 92 beingin the first or forward position in the direction of arrow 510 (FIG.16).

To unlock the second hinge/lock assembly 50 from the striker 54, withadditional reference to FIGS. 19A and 19B, the synchronizer 74 pulls theactuator rod 88 in a first direction, indicated by arrow 496, whichrotates the actuator lever 342 in the second rotatable direction. Theleg 342 a engages and moves the connector lever 338 in the firstrotatable direction which, in turn, engages and moves the pin 332 e torotate the ratchet 332 in the second rotatable direction. Movement ofthe connecting lever 338 and, specifically, the leg 338 c by theactuator rod 88 causes the leg 338 c to engage the leg 344 a of thesensor lever 344 thereby moving the sensor lever in the second rotatabledirection to a sensor lever second position corresponding to the ratchetdisengaged position wherein the sensor rod 92 mechanically communicateswith the synchronizer 74 by the rod 92 being in a retracted position inthe direction of arrow 500.

The ratchet 332 is moved in the second rotatable direction against theurging of the spring 334 to the disengaged position wherein the opposingcatch surface 332 a is removed as an obstruction to the latch 304. Withthe ratchet 332 in the disengaged position, the spring 330 moves thelatch 304 to the unlatched position which unlocks the second hinge/lockassembly 50 and allows removal of the striker 54 from the lock bodyrecess 308. More particularly, as the latch 304 moves toward theunlatched position, the latch 304 forcibly moves the striker 54 from thelock body recess 308 which causes the tailgate 10 to at least partiallymove toward the swing-open position (as shown in FIG. 19A). The stop 336limits movement of the latch 304 in the second rotatable direction byengaging a first leg 304 b of the latch. Thus, the stop 336 holds thelatch 304 in the unlatched position.

Provided the ratchet 332 remains in the disengaged position, the sensorlever 344 remains in the sensor lever second position and the rod 92remains in the retracted position. Thus, when the ratchet 332 is in thedisengaged position, the sensor rod 92 continues to mechanicallycommunicate to the synchronizer 74 that the second hinge/lock assembly50 is unlocked by remaining in the retracted position. Until the latch304 is re-latched onto the striker 54, the ratchet 332, due to itsprofile or shape, remains in the disengaged position. Thus, the ratchet332 remains in the disengaged position when the latch is in theunlatched position and/or the latch is moveable between the latchedposition and the unlatched position. The ratchet 284 is only in theengaged position when the latch is in the latched position. Moreparticularly, with additional reference to FIGS. 20A and 20B, when thestriker 54 is initially received or moved in the lock body recess 308and the latch recess 328 causing the striker 54 to partially rotate thelatch in the second rotatable direction against the urging of the spring330 toward the latched position, the ratchet remains in the disengagedposition.

The spring 334 urges the ratchet 332 and, more particularly, the leg 332b into the latch, but, until the latch is rotated to the latchedposition (shown in FIG. 15), the opposing catch surface 332 a of theratchet does not engage the catch surface 304 a of the latch. When thecatch surface 304 a finally passes the opposing catch surface 332 a(i.e., the latch 304 is in the latched position), the ratchet 332 movesinto the engaged position to hold the latch in the latched position.When the ratchet 332 is in the engaged position, the pin 332 e, incombination with the spring 340, causes the connecting lever 338 torotate in the second rotatable direction so that the connecting leverleg 338 c moves toward the actuator lever 342 which is retracted in thefirst rotatable direction. When the connecting lever leg 338 c moves inthe first rotatable direction, the sensor lever 344 also moves in thefirst rotatable direction. In the illustrated embodiment, as will bediscussed in more detail below, the sensor rod 92 is urged in thedirection of arrow 500 by spring 456 (FIG. 27) which urges the sensorlever 344 to rotate in the first rotatable direction to the first sensorlever position. The urging of the sensor lever 344 in the firstrotatable direction ensures that the leg 344 a also remains inengagement with the connecting lever leg 338 c. In another embodiment,the connecting lever second leg 338 c is replaced by a C-shaped legdefining a recess that receives the sensor lever leg 344 a. Thus,movement of the connecting lever in either the first or second rotatabledirections has the effect of moving the sensor lever to a correspondingposition.

With reference to FIGS. 21 and 22, the locking assembly 62 includes alatching assembly having a lock body 350 and latch 352. The lock body350 is secured to the tailgate and, more specifically, the tailgateframe 150 via conventional fasteners, such as rivets or bolts 354, sothat a lock body recess 356 defined in the lock body is aligned with andable to receive the striker 64 when the tailgate 10 is in the closedposition. The lock body 350 generally includes a first wall 350 a, asecond wall 350 b spaced from the first wall and at least one connectingwall 350 c extending between the first and second walls. The recess 356is provided through the at least one connecting wall 350 c and intoportions of the walls 350 a, 350 b.

In the illustrated embodiment, the striker 64 is generally U-shaped andis mounted to a bracket 358 with suitable radial flanges 360 formedintegrally with ends of the U-shaped striker 64. The bracket 358 ismounted to the pillar 56 of the vehicle V via conventional fasteners,such as rivets or bolts 362. When the tailgate 10 is in the closedposition, the striker 64 is received in the recess 356. A bumper 364,like bumpers 278 and 326, can be provided within the recess 356. Thelatch 352 is rotatably mounted to the lock body 350 via rivet 365 forselectively latching onto the striker 64 to lock the striker to the lockbody 350 thereby locking the locking assembly 62 to the striker 64 andthe pillar 56 of the vehicle V.

The latch 352 includes a latch recess 366 for receiving the striker 64.More particularly, as will be described in more detail below, when thetailgate is moved to the closed position from either the swing-openposition or the flip-down position and the striker 64 is received in therecesses 356,366, the striker 64 causes the latch 352 to move and,specifically, rotate about the striker 64 to a latched position (shownin FIG. 21) wherein the latch locks the striker 64 in the lock body 350.When the latch 352 is in the unlatched position (shown in FIG. 23A), thestriker 64 is freely moveable into and from the recesses 356,366.

The locking assembly 62 also includes a biasing means, such as torsionspring 368, rotatably urging the latch 352 in the first rotatabledirection (clockwise in FIG. 21) toward the unlatched position. Aratchet 370 is rotatably mounted to the lock body 350 adjacent the latch352 for selectively engaging the latch 352 and holding the latch in thelatched position. More particularly, the latch 352 includes a catchsurface 352 a that is selectively engaged by an opposing catch surface370 a defined on the ratchet 370. Another biasing means, such as torsionspring 372, rotatably urges the ratchet 370 in the second rotatabledirection (counterclockwise in FIG. 21) toward an engaging position,wherein the opposing catch surface 370 a is urged into engagement withthe latch 352. The ratchet 370 includes an extending portion 370 b thatengages a stop 374 to limit movement of the ratchet in the secondrotatable direction. The at least one connecting wall 350 c limitsmovement of the latch 352 in the first rotatable direction when theratchet 370 is in a disengaged position that allows movement of thelatch 352 between the latched position and the unlatched position.

When the tailgate is in the closed position and the locking assembly 62is in the latched or locked position, the striker 64 is received in thelock body recess 356 and the latch 352 is in the latched positionthereby locking the striker within the recess 356 and releasablyconnecting the striker 64 to the lock body 350, which also releasablyconnects the vehicle body to which the striker 64 is mounted to thetailgate to which the lock body 350 is mounted. Though the latch 352 isurged toward the unlatched position, the latch is held in the latchedposition by the ratchet 370 which is in the engaged position.Particularly, the opposing catch surface 370 a of the ratchet engagesthe catch surface 352 a of the latch to maintain the latch in thelatched position.

To unlock the locking assembly 60 from the striker 64, with additionalreference to FIGS. 23A and 23B, the synchronizer 74 pulls the actuatorrod 84 in the direction of arrow 476 which rotates an actuator lever 376in the second rotatable direction (counterclockwise in FIG. 23B). Thelever 376 is pivotally mounted to a flange 378 so that the lever 376 isapproximately normal relative to the latch 352 and the ratchet 370 andgenerally parallel to the tailgate 10. Movement of the lever 376, whichhas a first leg 376 a pivotally connected to the rod 84, in the secondrotatable direction causes a second leg 376 b of the lever to engage androtate the ratchet 370 in the first rotatable direction against theurging of the spring 372 to the disengaged position wherein the opposingcatch surface 370 a is removed as an obstruction to the latch 352. Withthe ratchet 370 in the disengaged position, the spring 368 moves thelatch 352 to the unlatched position which unlocks the locking assembly62 and allows removal of the striker 64 from the lock body 350. Moreparticularly, as the latch 352 moves toward the unlatched position, thelatch 352 forcibly moves the striker 64 from the lock body recess 356which causes the tailgate 10 to at least partially move toward one ofthe open positions (i.e., the swing-open position or the flip-downposition). The lock body wall 350 c limits movement of the latch 352 inthe first rotatable direction by engaging a first leg 352 b of thelatch.

With reference to FIG. 24-27, the synchronizer 74 is shown in a restingor tailgate closed position, wherein each of the assemblies 44,50,62 arelocked to their respective strikers and neither of the handles 80,86 arepulled or actuated. The synchronizer 74 includes a plurality of leversconnected to the tailgate for coordinating operation between the handleassemblies 70,72 and the hinge/lock and locking assemblies 44,50,62.More particularly, the synchronizer 74 includes (1) a first set oflevers 402 connected to the actuator rod 82, the sensor rod 92 and thehandle rod 76 and (2) a second set of levers 404 connected to theactuator rods 84,88, the sensor rod 90 and the handle cable 78. The setsof levers 402,404 are rotatably connected to a mounting bracket 406which is secured to the tailgate 10 via suitable fasteners, such asrivets or bolts 408. Thus, the sets of levers 402,404 are rotatablymounted to the tailgate 10. The bracket 406 includes a flange portion410 having a cable support 412 mounted thereto for supporting andguiding the cable 78 into the synchronizer 74.

The first set of levers 402 includes a first or upper handle lever 414pivotally connected to the upper handle rod 76 so that the lever 414moves when the handle 80 is moved. The lever 414 is pivotally mounted tothe bracket 406 by pivot member 416. The first set 402 additionallyincludes a first hinge/lock actuation lever 418 and a second hinge/locksensor lever 420. The actuation lever 418, which is adjacent the upperhandle lever 414, has a first arm 418 a pivotally connected to theactuation rod 82 and is pivotally mounted to the bracket 406 by thepivot member 416. As will be described in more detail below, theactuation lever 418 is selectively moveable by the upper handle 80 andis connected to the first hinge/lock assembly 44 so that the lever 418unlocks the first hinge/lock assembly when sufficiently moved by thehandle 80. The sensor lever 420 is pivotally connected to the sensor rod92 and pivotally mounted to the bracket 406 by a pivot member 422. Morespecifically, the sensor lever 420 is pivotally connected to an L-shapedportion or flange 424 of the bracket 406. A pin lever 426 is pivotallyconnected adjacent a first end 426 a to a first leg 420 a of the sensorlever and adjacent a second end 426 b to the actuation lever 418. Asecond leg 420 b is pivotally connected to the sensor rod 92.

In the illustrated embodiment, the pin lever 426 includes a pin 426 creceived through the sensor lever 420 to rotatably connect the pin lever426 to the sensor lever 420. The second end 426 b of the pin leverincludes another pin 426 d extending through an aperture or slot 428defined in a second arm 418 b of the actuation lever 418. The pin 426 dincludes radial portions or extensions 432 which prevent axial pulloutof the pin from the slot 428. The pin 426 d also extends through anopening 433 defined in the bracket 406. As will be described in moredetail below, the pin 426 d is selectively positionable for engagementwith an engaging portion 414 a of a first arm 414 b of the upper handlelever 414.

The second set of levers 404 includes a lower handle lever 434 pivotallyconnected to the cable 78 so that the lever 434 moves when the handle 86is moved. The lever 434 is pivotally mounted to the bracket 406 by pivotmember 436. The second set 404 additionally includes a second hinge/lockactuation lever 438, a first hinge/lock sensor lever 440 and a lockingassembly actuation lever 442. The actuation lever 438, which is adjacentthe lower handle lever 434, includes a first arm 438 a that is pivotallyconnected to the actuation rod 88 and is itself pivotally mounted to thebracket 406 by the pivot member 436. As will be described in more detailbelow, the actuation lever 438 is selectively moveable by the lowerhandle 86 and is connected to the second hinge/lock assembly 50 so thatthe lever 438 unlocks the second hinge/lock assembly when sufficientlymoved by the handle 86. The sensor lever 440 is pivotally connected tothe sensor rod 90 and pivotally mounted to the bracket 406 by pivotmember 444. More specifically, the sensor lever 440 is pivotallyconnected to an L-shaped portion or flange 446 of the bracket 406. A pinlever 448 is pivotally connected adjacent a first end 448 a to a firstleg 440 a of the sensor lever 440 and adjacent a second end 438 b to theactuation lever 438. A second leg 440 b is pivotally connected to thesensor rod 90.

In the illustrated embodiment, the pin lever 448 includes a pin 448 creceived through the sensor lever 440 to rotatably connect the pin lever448 to the sensor lever 440. The second end 448 b of the pin lever 448includes another pin 448 d extending through an aperture or slot 450defined in a second arm 438 b of the actuator lever 438. The pin 448 dincludes radial portions or extensions 452 which prevent axial pulloutof the pin from the slot 450. As will be described in more detail below,the pin 448 d is selectively positionable for engagement with anengaging portion 434 a of a first arm 434 b of the lower handle lever434. The locking assembly lever 442 includes a first arm 442 a pivotallyconnected to the rod 84.

As will be appreciated by those skilled in the art, a plurality ofsprings are provided for biasing or urging several of the levers in afirst or second rotatable direction. The springs are illustrated only inFIG. 27 and only schematically. All of the schematically illustratedsprings are shown having a first end connected to one of the levers anda second end connected to a schematically illustrated fixed member(which may be the bracket 406 or some other component of the tailgate10, such as the frame 150, for example). Those skilled in the art willappreciate that other biasing means could be used in place of theillustrated springs, including, for example, other springs (such astorsion springs), the orientation of a particular lever relative togravity, etc., and all such other means are to be considered within thescope of the present invention.

More particularly, the plurality of springs includes a spring 454connected to the first hinge/lock assembly actuation lever 418 andurging the lever to rotate in the second rotatable direction(counterclockwise in FIG. 27) about the pivot member 416. Another spring456 is connected to the second hinge/lock assembly sensor lever 420 andurges the lever 420 to rotate in the second rotatable direction aboutthe pivot member 422. Spring 458 is connected to the lower handle lever434 and urges the lever 434 to rotate in the first rotatable direction(clockwise in FIG. 27) about the pivot member 436. Spring 460 isconnected to the first hinge/lock assembly sensor lever 440 and urgesthe lever 440 to rotate in the first rotatable direction about the pivotmember 444. Spring 462 is connected to the locking assembly lever 442and urges the lever 442 to rotate in the first rotatable direction aboutthe pivot member 436.

As will be described more specifically below, FIGS. 28-32 illustrate theoperation of the synchronizer 74 in coordinating and mechanicallycommunicating with the handle assemblies 70,72 and the lock assemblies44,50,62. Based on the states or positions of the first and secondhinge/lock assemblies 44,50, as communicated by the sensor rods 90,92,the synchronizer 74 selectively enables or disables communicationbetween (1) the upper handle assembly 70 and the first hinge/lock andlocking assemblies 44,62 and (2) the lower handle assembly 72 and thesecond hinge/lock and locking assemblies 50,62. More particularly, ifthe first and second hinge/lock assemblies 44,50 are both latched ontotheir respective strikers 48,54, the sensor rods 90,92 mechanicallycommunicate the respective latched positions of the assemblies 44,50 tothe synchronizer 74 which then enables either of the handle assemblies70,72 to be operational for opening the tailgate 10.

If the first hinge/lock assembly 44 is unlatched or unlocked from thestriker 48, the sensor rod 90 mechanically communicates the unlatchedposition of the assembly 44 to the synchronizer 74 which then disablesthe lower handle assembly 72 from opening or unlatching the assemblies50,62. Conversely, if the first hinge/lock assembly 44 is latched orlocked, the sensor rod 90 mechanically communicates the latched positionof the assembly 44 to the synchronizer 74 which enables the lower handleassembly 72 to open or unlatch the assemblies 50,62. If the secondhinge/lock assembly 50 is unlatched or unlocked from the striker 54, thesensor rod 92 mechanically communicates the unlatched position of theassembly 50 to the synchronizer 74 which then disables the upper handleassembly 70 from opening or unlatching the assemblies 44,62. Conversely,if the second hinge/lock assembly 50 is latched or locked, the sensorrod 92 mechanically communicates the latched position of the assembly 50to the synchronizer 74 which enables the upper handle assembly 70 toopen or unlatch the assemblies 44,62. The synchronizer 74 additionallyprevents simultaneous operation of both handle assemblies 70,72 torelease all the assemblies 44,50,62 simultaneously. When the handleassemblies 70,72 are disabled from operating and unlatching theassemblies 44,50,62, the handles 80,86 are still permitted freedom ofmovement.

In operation, when the upper handle 80 (FIG. 2) is pulled, its stroke iscommunicated to the synchronizer 74 through rod 76. With reference toFIG. 28, pulling of the upper handle 80 causes the rod 76 to move towardthe synchronizer 74, in the direction of arrow 466, thereby rotating theupper handle lever 414 in the first rotatable direction or arrow 468. Ifthe second hinge/lock assembly 50 is in the locked or latched positionwhen the handle 80 is pulled, the synchronizer 74 connects the stroke ofthe rod 76 to the rods 82,84 which unlocks the assemblies 44,62 andenables the tailgate 10 to be opened toward the flip-down position. Moreparticularly, provided the tailgate 10 is closed and all the assemblies44,50,62 are locked (i.e., the synchronizer 74 starts from its restingposition shown in FIGS. 24-27), rotation of the lever 414 in thedirection of arrow 468 causes the engaging arm 414 a to engage andforcibly move the pin 426 d, which is in a first position. Since the pin426 d is received in the slot 428, forced movement of the pin 426 d bythe engaging arm 414 a causes rotation of the first hinge/lock actuationlever 418 in the first rotatable direction, represented by arrow 470,against the urging of the spring 454.

Rotation of the lever 418 in the direction of arrow 470 pulls the rod 82toward the synchronizer in the direction of arrow 472 which, asdescribed above, unlatches or unlocks the first hinge/lock assembly 44.Rotation of the lever 418 in the direction of arrow 470 also causes athird arm 418 c of the lever 418 having a first engaging portion 418 dto engage and forcibly move the second arm 442 b (and, morespecifically, an engaging portion 442 c of the second arm) of thelocking assembly lever 442 thereby rotating the lever 442, against theurging of the spring 462, in the second rotatable direction representedby arrow 474. Rotation of the lever 442 in the direction of arrow 474pulls the rod 84 toward the synchronizer in the direction of arrow 476which, as described above, unlatches or unlocks the locking assembly 62.

When the first hinge/lock assembly 44 is unlocked, the sensor rod 90moves to its retracted position, represented by arrow 478 due to themovement of the lever 292 (FIG. 12) when the first hinge/lock assemblyis in an unlocked condition, as described above. Pulling of the rod 90causes the sensor lever 440 to rotate in the second rotatable direction,represented by arrow 480, against the urging of the spring 460 whichcauses the pin lever 448 with the pin 448 d to move in the direction ofarrow 482 along the slot 450 to a second position. As will be describedin more detail below, movement of the pin 448 d along the slot 450 awayfrom the engaging portion 434 a of the lower handle lever 434 disengagesor disables use of the lower handle 86 for purposes of unlocking theassemblies 50,62.

With reference to FIG. 29, when the lower handle 86 (FIG. 2) is pulled,its stroke is communicated to the synchronizer 74 through the cable 78.More particularly, pulling of the lower handle 86 causes the cable tomove away from the synchronizer 74, in the direction of arrow 490,thereby rotating the lower handle lever 434 in the second rotatabledirection or arrow 492. If the second hinge/lock assembly 50 is in theunlocked or unlatched position when the handle 80 is pulled, thesynchronizer 74 does not connect the stroke of the rod 76 to the rods82,84 and the upper handle 80 is prevented from opening the tailgate 10.More particularly, provided the tailgate 10 is closed and all theassemblies 44,50,62 (i.e., the synchronizer 74 starts from its restingposition), rotation of the lever 434 in the direction of arrow 492causes the engaging arm 434 a to engage and forcibly move the pin 448 d,which is in a first position. Since the pin 448 d is received in theslot 450, forced movement of the pin 448 d by the engaging arm 434 acauses rotation of the second hinge/lock actuation lever 438 in thesecond rotatably direction, represented by arrow 494.

Rotation of the lever 438 in the direction of arrow 494 pulls the rod 88toward the synchronizer in the direction of arrow 496 which, asdescribed above, unlatches or unlocks the second hinge/lock assembly 50.Rotation of the lever 438 in the direction of arrow 494 also causes anengaging portion 438 c to engage a second engaging portion 442 d of thefirst arm 442 b of the lever 442 thereby rotating the lever 442, againstthe urging of the spring 462, in the second rotatable directionrepresented by arrow 498 which pulls lever 84 in the direction of arrow476 to unlock or unlatch the locking assembly 62.

When the second hinge/lock assembly 50 is unlocked, the sensor rod 92moves to its retracted position, represented by arrow 500 due to themovement of the lever 344 (FIG. 16) when the second hinge/lock assemblyis in an unlocked condition, as described above. Pulling of the rod 92causes the sensor lever 420 to rotate in the first rotatable direction,represented by arrow 502, against the urging of the spring 456 whichcauses the pin lever 426 with the pin 426 d to move in the direction ofarrow 504 along the slot 428 to a second position. As will be describedin more detail below, movement of the pin 426 d along the slot 428 awayfrom the engaging portion 414 a of the upper handle lever 414 disengagesor disables use of the upper handle 80 for purposes of unlocking theassemblies 44,62.

With reference to FIG. 30, the synchronizer 74 is configured to preventboth handles 80,86 from simultaneously unlocking the first and secondhinge/lock assemblies 44,50. Generally, one of the handles 80,86 willhave its stroke communicated to the synchronizer 74 prior to the otherof the handles 80,86, even when both handles are attempted to be pulledsimultaneously. As long as one of the handles 80,86 has its strokecommunicated to the synchronizer 74 prior to other of the handles 80,86,the handle having its stroke communicated last will be disengaged ordisabled and unable to unlock the assemblies to which it is otherwiseoperable to unlock. Should both handles 80,86 have their strokescommunicated to the synchronizer 74 simultaneously, an engagementbetween the first set of 402 and the second set of levers 404 preventsoperation of either of the handles and does not permit either of thehandles from unlocking any of the assemblies 44,50,62

For example, when the upper handle 80 is pulled, the rod 76 moves in thedirection of arrow 466 which rotates the upper handle lever 414 in thedirection of arrow 468. If, at approximately the same time, the lowerhandle 86 is pulled, the cable 78 moves in the direction of arrow 490which rotates the lower handle lever 434 in the direction of arrow 492.If the levers 414,434 rotate at the same time, then their respectiveengaging portions 414 a, 434 a simultaneously engage corresponding pins426 d, 448 d. As already discussed, movement of the pins 426 d, 448 d bythe portions 414 a, 438 a causes levers 418,438 to rotate, respectively,in the directions of arrows 470,494, i.e., the lever 418 rotatesclockwise in FIG. 30 and the lever 438 rotates counterclockwise in FIG.30. Rather than sufficiently rotating (i.e., some rotation of the levers414,434 can occur simultaneously but not sufficient rotation) to pullthe rods 82,88 and unlock the hinge/lock assemblies 44,50 or rotatingenough to engage and rotate lever 442 (to pull rod 84), thesimultaneously rotating levers 418,438 engage and obstruct one anotherand disable both handles 80,86 from operating any of the assemblies44,50,62. More particularly, third engaging portions 418 e, 438 d of thelevers 418,438 engage one another and prevent both levers from furtherrotating.

If the second hinge/lock assembly 50 is in the unlocked or unlatchedposition when the handle 80 is pulled, the synchronizer 74 does notconnect the stroke of the rod 76 to the rods 82,84 and the upper handle80 is prevented or disabled from opening the tailgate 10. However, evenwhen the upper handle 80 is prevented from opening the tailgate, theupper handle 80 is still moveable, just not operational. Moreparticularly, as already described with reference to FIG. 29, when thesecond hinge/lock assembly 50 is unlocked, the pin 426 d is moved awayfrom the engaging portion 414 a along the slot 428 to the secondposition. With additional reference to FIG. 31, with the pin 426 d movedaway from the engaging portion 414 a, movement of the upper handle 80 isstill permitted and its stroke (represented by arrow 466) is stillcommunicated to the synchronizer through the rod 76. However, rotationof the upper handle lever 414 does not result in the unlocking of thefirst hinge/lock assembly 44 (the second hinge/lock assembly 50 and thelocking assembly 62 are assumed to be unlocked in FIG. 31).

As illustrated in FIG. 31, rotation of the lever 414 as represented byarrow 468 does not result in rotation of any other levers. The engagingportion 414 a moves by, but does not engage or forcibly move, the pin426 d. Thus, the handle 80 is moveable and its stroke is stillcommunicated to the synchronizer 74, but the synchronizer does notconnect movement of the lever 414, which is caused by pulling of thehandle 80, with the first hinge/lock lever 418. Only when the sensor rod92 is returned to the normal position, which returns the pin 426 d toits engaging position adjacent the engaging portion 414 a, does thehandle 80 become operational for purposes of opening the firsthinge/lock assembly 44. Of course, the sensor rod 92 only returns to thenormal position when the second hinge/lock assembly 50 is re-latched orlocked.

If the first hinge/lock assembly 44 is in the unlocked or unlatchedposition when the handle 86 is pulled, the synchronizer 74 does notconnect the stroke of the cable 78 to the rods 84,88 and the lowerhandle 86 is prevented from opening the tailgate 10. However, as withthe upper handle 80, even when prevented from opening the tailgate, thelower handle 86 is still moveable, just not operational. Moreparticularly, as already described with reference to FIG. 28, when thefirst hinge/lock assembly 44 is unlocked the pin 448 d is moved awayfrom the engaging portion 434 a along the slot 450. With additionalreference to FIG. 32, with the pin 448 d moved away form the engagingportion 434 a, movement of the lower handle 86 is still permitted andits stroke (represented by arrow 490) is still communicated to thesynchronizer through the cable 78. However rotation of the lower handlelever 434 does not result in the unlocking of the second hinge/lockassembly 50 (the first hinge/lock assembly 44 and the locking assembly62 are assumed to be unlocked in FIG. 32).

As illustrated in FIG. 32, rotation of the lever 434 as represented byarrow 492 does not result in rotation of any other levers. The engagingportion 434 a moves by, but does not engage or forcibly move, the pin448 d. Thus, the handle 86 is moveable and its stroke is stillcommunicated to the synchronizer 74, but the synchronizer does notconnect movement of the lever 434, which is caused by pulling of thehandle 86, with the second hinge/lock assembly 50. Only when the sensorrod 90 is returned to the normal position, which returns the pin 448 dto its engaging position adjacent the engaging portion 434 a, does thehandle 86 become operational for purposes of opening the second/hingelock assembly 50. Of course, the sensor rod 90 only returns to thenormal position when the first hinge/lock assembly 44 is re-latched orlocked.

With reference to FIG. 33, the synchronizer 74 includes a fail safefeature that disables the first and second handles 80,86 in the event ofone or both of the sensor rods 90,92 failing or breaking or beingdisconnected from, respectively, the locking assemblies 44,50 and/or thesynchronizer 74. More particularly, if the sensor rod 92 is broken, asillustrated in FIG. 33, the synchronizer 74 does not connect the strokeof the rod 76 to the actuator rods 82,84 and the upper handle 80 isprevented or disabled from opening the tailgate 10. Specifically, if rod92 fails, the spring 456 rotates the lever 420 in the second rotatabledirection, as indicated by arrow 506, (counterclockwise in FIG. 33) andmoves the pin 426 d, through the pin lever 426, in the direction ofarrow 508 to a third position (the position shown in FIG. 33). In thethird position, the pin 426 d is moved away from the engaging portion414 a along the slot 428 in an opposite direction from the firstposition than the pin moves when moving to the second position. With thepin 426 d moved away from the engaging portion 414 a and in the thirdposition, movement of the upper handle 80 is still permitted and itsstroke, indicated by arrow 466, is still communicated to thesynchronizer 74 through the rod 76. However, rotation of the lever 414,as indicated by arrow 468, does not result in the unlocking of the firsthinge/lock assembly 44. As illustrated, rotation of lever 414 causes theengaging portion 414 a to move by, but not forcibly engage or move, thepin 426 d.

Similarly, if the sensor rod 90 is broken, as illustrated in FIG. 33,the synchronizer 74 does not connect the stroke of the cable 78 to theactuator rods 84,88 and the lower handle 86 is prevented or disabledfrom opening the tailgate 10. Specifically, if rod 90 fails, the spring460 rotates the lever 440 in the first rotatable direction, as indicatedby arrow 510, (clockwise in FIG. 33) and moves the pin 448 d, throughthe pin lever 448, in the direction of arrow 512 to a third position(the position shown in FIG. 33). In a third position, the pin 448 d ismoved away from the engaging portion 434 a along the slot 450 in anopposite direction from the first position than the pin moves whenmoving to the second position. With the pin 448 d moved away from theengaging portion 434 a and in the third position, movement of the lowerhandle 86 is still permitted and its stroke, as indicated by arrow 490,is still communicated to the synchronizer 74 through the cable 78.However, rotation of the lever 434, as indicated by the arrow 492, doesnot result in the unlocking of the second hinge/lock assembly 50. Asillustrated, rotation of the lever 434 causes the engaging portion 434 ato move by, but not forcibly engage or move, the pin 448 d.

The exemplary embodiment has been described with reference to theembodiments. Obviously, modifications and alterations will occur toothers upon reading and understanding the preceding detaileddescription. It is intended that the exemplary embodiment be construedas including all such modifications and alterations insofar as they comewithin the scope of the appended claims or the equivalents thereof.

1. A tailgate synchronizer for coordinating mechanical communicationbetween first and second handles mounted to a tailgate and first andsecond lock assemblies that selectively lock the tailgate to a vehiclebody, said synchronizer comprising: a first lock assembly actuator leverrotatably mounted to the tailgate and selectively moveable by the firsthandle, said first lock assembly actuator lever connected to the firstlock assembly so that said first lock assembly actuator lever unlocksthe first lock assembly when sufficiently moved by the first handle; anda second lock assembly actuator lever rotatably mounted to the tailgateand selectively moveable by the second handle, said second lock assemblyactuator lever connected to the second lock assembly so that said secondlock assembly actuator lever unlocks the second lock assembly whensufficiently moved by the second handle.
 2. The tailgate synchronizer ofclaim 1 further including: a first handle lever rotatably mounted to thetailgate adjacent said first lock assembly actuator lever and connectedto the first handle so that said first handle lever moves when the firsthandle is moved, said first handle lever moving said first lock assemblyactuator lever when the first handle is enabled and moved; and a secondhandle lever rotatably mounted to the tailgate adjacent said second lockassembly actuator lever and connected to the second handle so that saidsecond handle lever moves when the second handle is moved, said secondhandle lever moving said second handle actuator lever when the secondhandle is enabled and moved.
 3. The tailgate synchronizer of claim 2wherein said first handle lever is pivotally connected to a first handlerod that is connected to the first handle, actuation of the first handlemoves said first handle lever through said first handle rod, and saidsecond handle lever is pivotally connected to a second handle cable thatis connected to the second handle, actuation of the second handle movessaid second handle lever through said second handle cable.
 4. Thetailgate synchronizer of claim 2 wherein the first handle is enabledwhen the second lock assembly is locked and the second handle is enabledwhen the first lock assembly is locked.
 5. The tailgate synchronizer ofclaim 4 further including: a second lock assembly sensor lever rotatablymounted to the tailgate, said second sensor lever having a first leg anda second leg, said second leg connected to the second lock assembly; apin lever pivotally connected to said sensor lever first leg, said pinlever having a pin received through a slot defined in said firstactuator lever, said pin in a first position when the first handle isenabled and in a second position when the first handle is disabled; andwherein said pin engaged and movable by said first handle lever when insaid first position thereby allowing said first handle lever to movesaid first actuator lever, and said pin not engaged and moveable by saidfirst handle lever when in said second position thereby preventing saidfirst handle lever from moving said first actuator lever.
 6. Thetailgate synchronizer of claim 5 further including: a first assemblysensor lever rotatably mounted to the tailgate, said first sensor leverhaving a first sensor lever first leg and a first sensor lever secondleg, said first sensor lever second leg connected to the first lockassembly; a first assembly pin lever pivotally connected to said firstsensor lever first leg, said first assembly pin lever having a firstassembly pin received through a second actuator lever slot defined insaid second actuator lever, said first assembly pin in a first assemblypin first position when the second handle is enabled and in a firstassembly pin second position when the second handle is disabled; andwherein said first assembly pin engaged and moveable by said secondhandle lever when in said first assembly pin first position therebyallowing said first handle lever to move said first actuator lever, andsaid first assembly pin not engaged and moveable by said first handlelever when in said first assembly pin second position thereby preventingsaid first handle lever from moving said first actuator lever.
 7. Thetailgate synchronizer of claim 5 wherein a sensor rod connects thesecond lock assembly to said first sensor lever second leg, said sensorrod mechanically communicating a status of the second lock assembly bymoving, through said sensor lever and said pin lever, said pin to saidfirst position when the second lock assembly is locked and moving saidpin to said second position when the second lock assembly is unlocked.8. The tailgate synchronizer of claim 7 wherein said second lockassembly sensor lever is rotatably urged so that said pin is moved to athird position if said sensor rod becomes disconnected from one of saidfirst sensor lever and said second lock assembly, said pin notengageable and movable by said first handle lever when in said thirdposition thereby preventing said first handle lever from moving saidfirst actuator lever.
 9. The tailgate synchronizer of claim 4 furtherincluding: a first lock assembly sensor lever rotatably mounted to thetailgate, said first sensor lever having a first leg and a second leg,said second leg connected to the first lock assembly; a pin leverpivotally connected to said sensor lever first leg, said pin leverhaving a pin received through a slot defined in said second actuatorlever, said pin in a first position when the second handle is enabledand in a second position when the second handle is disabled; and whereinsaid pin engaged and movable by said second handle lever when in saidfirst position thereby allowing said second handle lever to move saidsecond actuator lever, and said pin not engaged and moveable by saidsecond handle lever when in said second position thereby preventing saidsecond handle lever from moving said second actuator lever.
 10. Thetailgate synchronizer of claim 9 further including: a locking assemblylever rotatably mounted to the tailgate and connected to a lockingassembly that selectively locks the tailgate to the vehicle body, saidlocking assembly lever rotatably movable by said pin when said pin is insaid first position and forcibly moved by said second actuator lever,movement of said locking assembly lever by said pin unlocks said lockingassembly.
 11. The tailgate synchronizer of claim 1 wherein said firstlock assembly actuator lever is not sufficiently movable to unlock thefirst lock assembly when the second lock assembly is unlocked and thefirst handle is moved, and said second lock assembly actuator lever isnot sufficiently movable to unlock the second lock assembly when thefirst lock assembly is unlocked and the second handle is moved.
 12. Thetailgate synchronizer of claim 1 wherein said first lock assemblyactuator lever and said second lock assembly actuator lever areprevented from sufficiently moving simultaneously.
 13. The tailgatesynchronizer of claim 12 wherein said first actuator lever includes afirst actuator lever engaging portion and said second actuator leverincludes a second actuator lever engaging portion, said engagingportions engage and obstruct one another upon simultaneous rotation ofsaid first and second actuator levers thereby preventing sufficientmovement of said first and second actuator levers to unlock the firstand second lock assemblies.
 14. The tailgate synchronizer of claim 1wherein said first lock assembly actuator lever first arm is pivotallyconnected to a first lock assembly actuator rod that is connected to thefirst lock assembly, said first actuator rod unlocking the first lockassembly when said first actuator lever is sufficiently moved by thefirst handle, and said second lock assembly actuator lever first arm ispivotally connected to a second lock assembly actuator rod that isconnected to the second lock assembly, said second actuator rodunlocking the second lock assembly when said second actuator lever issufficiently moved by the second handle.
 15. A tailgate synchronizer forselectively enabling a first handle to unlock a first lock assemblybased on the status of a second lock assembly, the first and second lockassemblies releasably locking a tailgate, to which the synchronizer ismounted, to a vehicle body, said tailgate synchronizer comprising: amounting bracket fixedly secured to the tailgate; a first lock actuatorlever pivotally mounted to said mounting bracket by a first pivotmember, said first lock actuator lever pivotally connected to a firstlock rod that connects to the first lock assembly, movement of saidfirst lock actuator lever in a first rotatable direction moves saidfirst lock rod to unlock the first lock assembly; a first handle leverpivotally mounted to said mounting bracket by said first pivot member,said first handle lever connected to a first handle rod that connects tothe first handle, actuation of the handle causes said first handle leverto move in said first rotatable direction; and a pin connected to thesecond lock assembly and received through an aperture defined in saidfirst lock actuator lever, said pin movable along said aperture to afirst position corresponding to an unlocked position of the second lockassembly and a second position corresponding to a locked position of thesecond lock assembly, said first lock actuator lever only moveable insaid first rotatable direction by said first handle lever when said pinis in said first position and said first handle lever is moved in saidfirst rotatable direction.
 16. The tailgate synchronizer of claim 15further including: a sensor lever pivotally mounted to said mountingbracket by a second pivot member spaced from said first pivot member,said sensor lever having a second leg pivotally connected to a sensorrod that connects to the second lock assembly and a first leg pivotallyconnected to a pin lever, said pin lever having said pin disposedthereon so that a status of the second lock assembly is mechanicallycommunicated to said pin by said sensor rod, said sensor lever and saidpin lever.
 17. The tailgate synchronizer of claim 15 further including:a second lock actuator lever pivotally mounted to said mounting bracketby a second pivot member, said second lock actuator lever pivotallyconnected to a second lock rod that connects to the second lockassembly, movement of said second lock actuator lever in a secondrotatably direction pulls said second lock rod to unlock the second lockassembly; a second handle lever pivotally mounted to said mountingbracket by said second pivot member, said second handle lever connectedto a second handle rod that connects to a second handle, pulling of thesecond handle causes said second handle lever to move in said secondrotatable direction; a first lock assembly pin connected to the firstlock assembly and received through a second lock actuator lever aperturedefined in said second lock actuator lever, said first lock assembly pinmovable along said second lock actuator lever aperture to a firstposition corresponding to an unlocked position of the first lockassembly and a second position corresponding to a locked position of thefirst lock assembly, said second lock actuator lever only moveable insaid second rotatable direction by said second handle lever when saidfirst lock assembly pin is in said first position and said second handlelever is moved in said second rotatable direction.
 18. A tailgatesynchronizer mounted to a tailgate for selectively allowing a firsthandle to unlock a first lock assembly based on the locked or unlockedcondition of a second lock assembly, the first and second lockassemblies each releasably locking the tailgate to a vehicle body, saidtailgate synchronizer comprising: a first lock actuator lever rotatablymounted to a tailgate and connected to a first lock assembly forunlocking the first lock assembly when sufficiently moved in a firstrotatable direction; a first handle lever rotatably mounted to thetailgate and connected to a first handle for moving in said firstrotatable direction upon actuation of said first handle; and a means forselectively rotating said first lock actuator lever in said firstrotatable direction when said first handle lever is rotated in saidfirst rotatable direction.
 19. The tailgate synchronizer of claim 18wherein said first handle lever rotating in said first rotatabledirection forcibly moving said first lock actuator lever in said firstrotatable direction when the second lock assembly is locked, and saidfirst handle lever rotating in said first direction without moving saidfirst lock actuator lever when the second lock assembly is unlocked. 20.The tailgate synchronizer of claim 18 wherein said means for selectivelyrotating said first lock actuator lever includes: a pin connected to thesecond lock assembly and received through an aperture defined in saidfirst lock actuator lever, said pin movable along said aperture to afirst position corresponding to an unlocked position of the second lockassembly and a second position corresponding to a locked position of thesecond lock assembly, said first lock actuator lever only moveable insaid first rotatably direction by said first handle lever when said pinin said first position and said first handle lever is moved in saidfirst rotatable direction.
 21. The tailgate synchronizer of claim 20wherein said means for selectively rotating said first lock actuatorlever further includes: a sensor lever rotatably mounted to the tailgateand having a first leg connected to the second lock assembly; and a pinlever pivotally connected to a second leg of said sensor lever, said pinextending from said pin lever.